Restrictive regulations concerning the toxicity of certain compounds and the use and disposal of solvents present in the liquid epoxy protection system have been analyzed in this work to evaluate powder coatings as an alternative in the protection of aerosol aluminum cans, which are employed in cosmetics and pharmaceutical product packaging. In this paper, the chemical resistance of polyester and mixed epoxy-polyester powder coatings is assessed, considering different aggressive environments employed in healthcare commercial products. The samples’ performances are also compared with the currently used liquid organic coatings. The pack test has been used to evaluate the protective system behavior in contact with both the liquid and the gaseous part of the cosmetic product. However, the visual observation, required by the test, enabled the highlight of only very evident degradation phenomena. The chemical resistance of the powder coatings has proved to be appropriate only for less aggressive environment, where the critical compounds are propellants, propane, butane and isobutane. When exposed to other environments containing alcohol, water and dimethyl ether, most samples have been susceptible to layer degradation phenomena. Polyester layers lose their corrosion protection properties. Epoxy systems, instead, result more performant than polyester resins, but they particularly suffer from the contact with dimethyl ether.
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